How to Replace a Fuel Hose

Fuel hoses comes in many different locations on vehicles. On older vehicles, there are steel lines from the fuel tank to the carburetor or injectors of a fuel system. Some of the older vehicles have short fuel hoses that connect the steel line to the fuel pump, fuel tank, and carburetor. These hoses over time tend to weaken and split causing gasoline or diesel to leak out.

From 1996 through today, vehicles have become more sophisticated using more advanced fuel injection systems. All of the vehicles that operate on gasoline have a supply line, return line, and a vapor line. These lines are plastic and crack over time as they wear out. These lines are not protected so they are subject to failure at any time as debris distorts them.

There are several forms of fuel hoses: rubber with adhesive liners, plastic or carbon fiber, or steel or aluminum.

Rubber fuel hoses are more common on older vehicles and diesel industries. When it comes to adjusting a fuel hose that needs to be moved all the time, the rubber hose is the best choice to use.

Plastic hoses or known as carbon fiber hose are the most common hose used today on many vehicles. This type of hose is very durable and can hold up to 250 pounds per square inch of pressure. The plastic hose helps keep the fuel cool for best performance and lowers the amount of vapors. Plastic hoses are subject to breakage very easily if the hose were tomove. Most of the plastic hoses have a quick disconnect fitting to attach other plastic hoses or even rubber hoses.

Steel and aluminum hoses are also commonly found on older vehicles and newer vehicles. These hoses are known as fuel lines. The lines are extremely durable and can hold pressures up to 1,200 pounds per square inch (psi). However, the lines are subject to bending and kinking, which causes a restriction. The restriction can cause the pressure to spike farther than 1,200 psi causing the line to rupture. Plus, the line heats up in hotter climates making the fuel boil.

Fuel is sprayed into the combustion chamber at an atomization rate. If the fuel has too much vapor or is boiling, the fuel enters the combustion chamber as a vapor which causes a loss of power.

Note: It is recommended to replace the fuel hoses with original manufacturer equipment (OEM). Aftermarket fuel hoses may not align up, may have the wrong quick disconnect, or may be too long or short.

There are several engine light codes related to the fuel hose on vehicles with computers:

Part 4 of 6: Checking for leaks

Step 2: Tighten the battery clamp up tight. Ensure that the connection is good.

Note: If you did not have a nine volt battery saver, you will have to reset all of the
settings in your vehicle, like your radio, electric seats, and electric mirrors.

Step 3: Turn the ignition key on. Listen for the fuel pump to activate and turn off the ignition after the fuel pump stops making noise.

Note: You will need to cycle the ignition key on and off 3 to 4 time to ensure all the fuel lines are full of fuel.

Step 4: Use a combustible gas detector and check all of the connections for any leaks. Sniff the air for any fuel odors.

Part 5 of 6: Lowering the vehicle

Step 1: Raise the vehicle. Using a floor jack, lift under the vehicle at its specified jacking points until the wheels are completely off the ground.

Step 2: Remove the jack stands. Keep them far away from the vehicle.

Step 3: Lower the vehicle to where all four wheels are on the ground. Pull out the
jack and put it aside.

Step 4: Remove the wheel chocks.

Part 6 of 6: Test drive the vehicle

Step 1: Drive the vehicle around the block. During the test, go over different bumps
allowing the fuel to slosh around inside the fuel lines.

Step 2: Monitor the dash for the fuel level and for any engine light to appear.

If your engine light comes on after replacing the fuel hose, then there may be further diagnosis of the fuel
system or a possible electrical issue within the fuel
system. If the problem persists, then you should seek out help from one of YourMechanic’s certified mechanics that can inspect the fuel hose and perform a replacement if needed.

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